Method of molding



Nov. 7, 1961 w. s. KNlFFlN, JR 3,007,692

METHOD OF MOLDING Filed Oct. 29, 1959 s Sheets-Sheet 1 IOB INVENTOR. Walter G. Kn/f fin, Jr:

His Attorney Nov. 7, 1961 w. G. KNlFFlN, JR 3,007,692

METHOD OF MOLDING Filed Oct. 29, 1959 6 Sheets-Sheet P;

- IN V EN TOR.

Walter G. Kn/ff/n, Jr BY His A fro/nay Nov. 7, 1961 w. G. KNIFFIN, JR 3,

METHOD OF MOLDING Filed Oct. 29, 1959 I e Sheets-Sheet :s

INVENTOR. Waller 6T Kn/ffm, Jr:

- His Af/orney Nov. 7, 1961 w. G. KNIFFIN, JR

METHOD OF MOLDING Filed 001;. 29, 1959 6 Sheets-Sheet 4 INVENTOR. Wal/erGI/(m'ffin, Jr

H/s Afforney Nov. 7, 1961 w. G. KNIFFIN, JR

METHOD OF MOLDING 6 Sheets-Sheet 6 Filed 001;. 29, 1959 Fig.6a

"INVENTOR. Walter G. Kn/Tfin, J1:

His Attorney ice 3,007,692 METHQD F MGLDING Walter G. Knitiin, .lr., Dayton, Ghio, assignor to General Motors Corporation, Detroit, Mich, a corporation of Delaware Filed Get. 2?, 1959, Ser. No. 849,518 3 Claims. (Cl. 267i) This invention relates to manufacture of elastomeric articles, and, particularly, to achievement of preloading of elastomeric mounting parts by means of a molding procedure.

An object of this invention is to provide a new and improved molding procedure whereby there is achieved a prestressing of elastomeric articles of manufacture needed for vibration and shock absorption in support and mounting of members relative to each other.

Another object of this invention is to provide a molding procedure whereby preloading of elastomeric articles of manufacture is accomplished with a minimum number of parts as well as a minimum of time, costs, and mate rial such that separate elastomeric portions are molded under complementary conditions in sequence so as to have the portions exert forces upon each other at all times.

Another object of this invention is to provide a molding procedure including steps of bonding a first quantity of elastomeric material relative to at least one of a pair of members spaced from each other, stressing the first elastomeric material to a distorted condition by movement of the members relative to each other under force such as tension, compression, shear, as well as torsion, maintaining the first elastomeric material under the distorted condition and simultaneously molding a second quantity of elastomeric material in a position continuous with the members as well as the first elastomeric material, and releasing the first elastomeric material from the distorted condition to an equilibrium condition in which the first and second quantities of elastomeric material exert complementary forces in balance relative to each other such that preloading under opposite forces is effected by the first and second quantities of elastomeric material relative to the pair of members.

Another object of this invention is to provide a unitary support assembly including a pair of mounting members, a first resilient means held relative to at least one of the mounting members under a stress that results from force to hold the means relative to the members under tension, compression, shear as well as torsion, and a second resilient means also secured to each of the mounting members under an opposing stress complementary to establish an equilibrium condition of preloading in opposite directions.

Another object of this invention is to provide a molding procedure including steps of providing a pair of mounting members in spaced relation to each other, sequentially molding therebetween multiple resilient portions of separate quantities of elastomeric material that can be soft as well as relatively harder, maintaining force to distort at least one quantity of elastomeric material to a predetermined condition during molding of a subsequent portion, and releasing the maintaining of force to permit attaining of an equilibrium condition of forces of distortion between at least a pair of resilient portions molded between the mounting members.

Further objects and advantages of the present invention will be apparent from the following description, reference being had to the accompanying drawings wherein preferred embodiments of the present invention are clearly shown.

In the drawings:

FIGURES 1a, 1b and 1c illustrate features of the present invention for support members and elastomen'c portions at least one of which is adapted initially to be stressed under tension and which finally reach an equilibrium condition wherein there is a resulting prestressing of the portions relative to each other and the support members.

FIGURES 2a, 2b, and 20 as well as FIGURES 3a, 3b, and 3c illustrate features of the present invention for support members and elastomeric portions at least one of which is adapted initially to be stressed under compression and which finally reach an equilibrium condition wherein there is a resulting prestressing of the portions relative to each other and the support members.

FIGURES 4a, 4b, and 4:: illustrate in end-sectioned perspective views further features of the present invention for support members and elastomeric portions at least one of which is adapted initially to be stressed under shear and which finally reach an equilibrium condition wherein there is a resulting prestressing of the portions relative to each other and the support members.

FIGURES 5a, 5b, and 5c illustrate in perspective partially sectioned side view features of the present invention for support members and elastomeric portions at least one of which is adapted initially to be stressed in torsion or twisting and which finally reached an equilibrium condition wherein there is a resulting prcstressing of the portions relative to each other and. support members.

FIGURE 6 is an end view of support members and elastomeric means further modified in accordance with cross-sectional views of FIGURES 6a and. 612 both taken along line xx in FIGURE 6 and both representing support members and elastomeric portions at least one of which is adapted initially to be stressed in torsion or twisting prior to obtaining an equilibrium condition wherein there is a resulting preloading of the portions torsionally as well as in possible shear relative to each other and the support members.

The drawings illustrate steps of a molding procedure that comprehends use of multiple moldings wherein at least one part is subjected to force for stressing such as tension, compression, shear as well as torsion while a further part is molded relative thereto in a condition initially free and unstressed and finally reaching a prestressed condition of equilibrium of forces complementary to prestressing of the first part which is released from its distorted condition so as to attempt to return to a free and unstressed condition that it is prevented from attaining due to molding of the further part relative thereto. The basic principles of the present invention are useful for resilient mountings such as provided as engine supports, vehicle suspension bushings for shackles, and the like. FIGURES 1a 117, and le illustrate sequentially steps in a molding procedure for accomplishing dual-prestressing of elastomeric means relative to each other and relative to mounting parts therefor. In FIGURE 1a there is shown a side view of a plate-like insert, mounting member, or support means 10s having laterally extending side and edge portions relative to which a suitable opening or bracket can be provided for fastening relative to a frame, chassis, unitized body construction and the like. The shape of the insert or mounting member 16s can be square, rectangular, circular and even any irregular disc-like configuration dependiug upon the specific requirements for a location relative to which the resilient mounting is to be provided. Also shown in FIGURE 1 is an. additional or intermediate plate-like means 10i having a central aperture 10a through which there is fitted a threaded bolt 1% having a head portion 10h at one end on one side of the intermediate means 10i in a location surrounding the aperture w. This bolt 10b serves as a force transmitting means relative to the intermediate plate-like means ltli used for eifecting a distorted condition upon a first or primary quantity, portion or means l lf of elastomeric material bonded securely along interfaces of the elastomeric portion ltlf relative to head portion lil h and one side of the intermediate means ltli and one side or surface of mounting member ills. The first elastomeric portion 16f is formed to any suitable shape along its radially outer periphery or along lateral outer sides. For example, a square or rectangular box or a cylindrical sleeve may be fitted over the outer or lateral peripheral surface of the first elastomeric portion lily such that elastomeric material can be injected, molded, and cured in situ in secured and bonded relation to the one surface of the mounting member ills as Well as the head portion lilh and one surface of intermediate means 161'. Next there is the step of providing a further or top insert, mounting member, or support means tilt in spaced relation to the first mounting member 10s as established by a combination spacing and molding means lt m shown in FIGURE lb. The spacing and molding means ltlm can have any suitable shape so as to form a square, rectangular, cylindrical and the like configuration. The spacing and molding means Ilfim can have a suitable opening through which elastomeric material can be injected in a Well known manner. However, in accordance with the present invention, prior to injection of molding or elastomeric material relative to a space or cavity within the confines of the spacing and molding means lillm it is necessary that the first quantity or portion of elastomeric material 149 be stressed to a distorted condition as represented in FIGURE lb. The top insertor mounting member Tilt has a centrally located passage 10p through which the-threaded bolt or force-transmitting means 1% projects and is adapted to receive a nut or force adjusting means 10a in threaded relationship thereto. Outer edge portion the of the top insert or second mounting member 1%! is caused to abut against one edge or end of the spacing and molding means itlm that abuts at an opposite end or edge along a peripheral end portion 10E of the first insert or mounting member ltls. Tightening of the nut ltln relative to the mounting member ltit effects distortion, stretching, and tensioning of the first quantity or portion of elastomeric material ltlf such that the latter becomes centrally contracted or concave in configuration in a location indicated by numeral tile. The mounting members fills and Tilt as well as the spacing and molding means ltlm must be made of rigid material such as metal that is not readily deformed or bent and that is compatible for bonding relativeto resilient or elastomeric material. The nut ltln and threaded body portion 10b of the bolt provide for adjusting of stressing such as tensioning of the first quantityor portion or" elastomeric material 10). The rigidity of the mounting members 19s and 101 as well asof the spacing and molding means lilm make possible a step of maintaining force to distort the first quantity or portion of elastomeric material ill to permit simultaneous molding of a second quantity or portion 10x of rmilient material in a location around or adjacent to the primaryquantity or portion 16 This molding of the secondary portion 19x occurs simultaneously :while maintaining stressing such as tensioning of the primary quantity or portion 10]. There is a curing of the secondary portion 10x under conditions illustrated in FIG- URE 1b and then the secondary portion 10x is bonded and secured relative to interfacesof mounting members 10s and 1th as well as intermediate means ltlit Aninner surface of the spacing and molding means ltlm can be coated with asuitable covering such as tetrafiuoroethylene that prevents sticking of elastomeric material relative thereto during curing of the latter. Finally, there is a removing or releasing of stressing such as tension on the primary molding or portion 10] of elastomeric material as illustrated in FIGURE 1c. 7

During the removing or releasing step illustrated in FIGURE 10, the first portion lilf of elastomeric material tends or seeks to return to an unstressed condition such as illustrated in FIGURE la, but the secondary portion ltix of elastomeric material is bonded in situ relative to the first portion lily so that the latter can return only part way to its initially unstressed condition. In FlGURE 1c the first portion lily has been permitted to attain an equilibrium condition still under predetermined tensioning as evidenced by a sli htly smaller degree of curvature in a location such as ltlk still contracted to a concave configuration now complementary to a laterally inwardly jutting portion lllj. By releasing of maintaining stressing on the primary portion'ltlf due to removal of nut 14in on the threaded body portion lilb of the bolt, there results a dual preloading of a unitary support assembly generally indicated by numeral lit in FIGURE 1c such that the primary portion 19f of elastomeric material comes to an equilibrium condition in tension and the secondary portion ltlx of elastomeric material comes to equilibrium in compression due to interaction of continuous surfaces along locations iii-k and 10f of first and second elastomeric portions respectively. A slight external bulging 108 occurs alon a laterally outer periphery of the second elastomeric portion Mix and this is illustrated in a slightly exaggerated state in FEGURE 1c. The primary and secondary molded portions can take a plurality of related shapes to meet specific requirements for control of preloading, hysteresis of elastomeric materials, rate of rebound, spacing between mounting members ltls and ltlf, loading such as determined by weight of an engine for example, vibration tuning with respect to shocks to be resiliently absorbed and counteracted, hardness of the first and second portions respectively, balancing of a load such as an engine relative to a chassis or body construction and additional design parameters such as must be met for resilient mountings adapted for use as supports in motor velt'cles. In the embodiment of FIGURE 10 the secondary molded portion includes a laterally inwardly extending snubbing or bumper portion 101 that is longitudinally in alignment with one end of the first elastomeric portion ltd and one side of intermediate means lili at a location laterally outside the body portion 1912 of the bolt. In accordance with the present invention, a balance of the physical properties of elastomeric material, prir ary surface areas, secondary surface areas and degree of preloading or prestressing can effectively produce assembly properties which can be mechanically conditioned and varied to produce any status of dual preloading which cannot be obtained in single moldings. Virtually every characteristic of a resilient mounting for example, can be varied mechanically during the molding process or procedure in accordance With the present invention.

Another example of a molding procedure in accordance with the present invention is provided in FIGURES 2a, 2b and 2c as well as in FIGURES 3a, 3b and 30 wherein prestressing such as compressing of the first or primary portions ids and 365 respectively occurs. First and second mounting means or members 20s, Zilt, 39s and 34% respectively are shown in predetermined spaced relationship to each other. During stressing and compressing of the first quantity or portion of elastomeric materials 26; and 30 illustrated in FIGURES 2b and 312 respectively a secondary quantity or portion of elastomeric material represented by numerals 20x and 30x respectively is molded to be contiguous with the insert or mounting members 26s, 2dr, Bits, and Silt, respectively, and releasing of the compression results in attaining of an equilibrium condition as illustrated in FIGURES 2c and 3c respectively. The configuration of the first portions Zllf and 30f difiers from a configuration illustrated in FIGURE 10 in that the first and second elastomeric portions are new bonded along interfaces relative to mounting members so as to come to an equilibrium condition under which the primary portions 2th and 36 remain in compression While the secondary molded portions come to equilibrium in tension. This condition is evidenced in FIGURES 2c and 3c by complementary relationship of laterally outwardly bulging in a location such as 203 along a surface contiguous with a laterally inner surface of the second portion 292: having a concave or curved configuration 20 and having a contracted outer periphery as represented by reference numeral 20K in FIGURE 20. Similar bulging is shown in FIGURE 30 in a location represented by reference numeral 393 for the primary portion 30f and reference numerals 3ilj and SitiK for the secondary portion 30x in FIGURE 30. The insert for mounting member 26s has an aperture 20a through which a threaded end or body portion 20b of a bolt can pass. A head portion Ziih of this bolt abuts against an inner portion of intermediate means 291' having a cut-out 20c through which the body portion 20b can pass. Since the stressing for the embodiment of FIGURES 2a and 3a involves compression of the first elastomeric portion 20 molded into any desired shape, it is not necessary that bonding or securing of the first elastomeric portion 20 occurs relative to a pair of spaced plate-like members. As indicated in FIGURE 2a the first elastomeric portion 20f is secured or bonded only relative to a surface on one side of the intermediate means Zili and then a nut 20:1 shown in FIGURE 2b effects compressing of the first elastomen'c portion 20s by tightening of the nut relative to the threaded end of the body portion 20b of the bolt having head portion 20k to pull the intermediate means 261' snugly toward the first mounting member 20s thereby compressing the first elastomeric portion 26 so as to have an excessive bulging portion Zbk. Upon removing or releasing of the stressing force by removal of the nut Ziln, the first elastomeric portion 20 attains an equilibrium condition as illustrated in FIGURE 20. A similar equilibrium condition is illustrated in FIGURE 30 in a view of a unitary support assembly generally indicated by numeral 3% and not having the intermediate means such as 201'. The unitary support assembly 30 requires only a minimum number of parts and full compression of the first elastomeric portion 30f can be accomplished by externally pressing together the mounting members 30s and Silt so as to effect bulging at 20k in the first elastomeric portion 3% as illustrated in FIGURE 3b. The first elastomeric portion 30f is molded and cured in situ in an unstressed condition relative to intersurfaces of mounting members 305 and 301 as shown in FIGURE 3a. In FIGURE 3b the elastomeric material of the secondary portion 30x has been molded and cured in contiguous relation with the first elastomeric portion 39). Stressing and preloading of both first and second elastomeric portions 39 and 30x respectively is illustrated in FIGURE 3c. It is to be understood that where the primary elastomeric portion is used in compression, bonding is not essential but may have advantages. Also, when the primary elastomeric portion is in tension, adhesion of the secondary elastomeric molded portion relative to the first elastomeric portion under predetermined design conditions may not be essential. As a further modification, there can be a coating of interfaces of elastomeric portions with friction reducing materials such as polytetrafiuoroethylene, molybdenum sulfide, wax, soap stone, soap, and the like for obtaining control of prestressing and preloading characteristics of the first and second elastomeric portions relative to each other. It is also possible that interfaces of the first and second elastomeric portions can be cut and slit or grooved relative to each other so as to provide intermeshing teeth or surfaces to provide further control of action between interfaces. It is to be understood that for each of the embodiments described thus far, a suitable provision is to be made for mounting of the inserts or support means for use in an environment described and illustrated in a patent, 2,903,208, Everitt, issued September 8, 1959, and belonging to the assignee of the present invention.

For resilient mountings subjected to lateral deflections, it is possible to provide p-restressing of a .resilient mounting in accordance with the present invention by a molding procedure illustrated sequentially by the views of FIG- URES 4a, 4b, and 40. Insert means ids and 4dr are provided in predetermined spaced relationship to each other and each having handles or eyelets 49/1 for engagement by a suitable fastening means such as a hook or bracket (not shown). Initially, the inserts or mounting members 40s and 401 are in substantially parallel alignment in locations laterally adjacent to each other and a first elastomen'c portion 49s is molded and cured in situ in secured and bonded relationship with opposite surfaces of the inserts or mounting members dds and 40!. Then while maintaining a stressed condition such as shear as illustrated in FIGURE 4b, the first quantities or portions 40f of elastomeric material are distorted. due to movement of mounting members ids and dill longitudinally relative to each other in the directions of arrows s and t, respectively, there is a step of simultaneously molding a secondary elastomeric quantity or portion 40x in a location in between or to one side of the first quantity or portion 40 of elastomeric material. It is to be understood that at least one section or portion of the first and second quantities of elastomeric materials must be provided. FIGURE 40 illustrates the unitary support assembly now generally indicated by numeral 40 and including the mounting members 40s and 4th on opposite sides of first and second elastomeric portions in an equilibrium condition of stressing wherein the first portion of elastomeric material Mix is resiliently hindered from returning to an initially free and unstressed condition of FIGURE 4a because of the provision of additional or secondary resilient portion 4dr. Shots or quantities of elastomeric materiais can be injected or supplied sequentially with :an initially molded portion such as 40f in shear and the elastomeric portions can have any desired shape and configuration as required by a particular resilient mounting.

FIGURES 5a, 5b and 50 further illustrate a molding procedure and unitary support assembly in accordance with the present invention. A pair of annular discs or plate-like mounting or support members Ellis and 501 each having eyelets such as hook members or fastening portions Siih are provided in substantially parallel relation to each other and spaced at predetermined distance laterally away from each other. A first elastomeric portion 5b) is molded so as to be bonded and secured in situ relative to surfaces of the plate-like members Sits and 501 as shown in FIGURE 5a and then one mounting member such as 5th is twisted or stressed torsionally by turning in a clockwise direction, for example, as represented by arrow A so as to bring the handle or book means Sfih of member 591 into a position transverse with respect to a position of handle or member 5011 of the other mounting member Sits. This transverse relationship of the hook members or means is used to illustrate conveniently the turning or twisting of the first elastomeric portion 50 into a distorted condition as represented by the View of FIGURE 5b. While maintaining this distorted condition, a second elastomeric portion Silx is molded in situ laterally on at least one side of the first elastomen'c portion Siis. FIGURE 50 represents a unitary support assembly generally indicated by numeral 50 in which first and second elastomeric portions 50x and 50s are contiguous and bonded or secured relative to each other as well as relative to the mounting members 50s and 561. The first and second elastomeric portions as illustrated in FIGURE 5c are in an equilibrium condition in which the second elastomeric portion 50x hinders return of the first elastomeric portion 50 to a free and unstressed condition. Small arrows represented by a reference 0 indicate torsional force balanced by force represented by small arrows x in secondary elastomeric portions 50x.

The angular position of hook means 50h onmounting member 591 relative to the flush side view of the hook means 5011 of member Sils represents further the equilibrium condition whereby there is a dual preloading and prestressing of first and second elastorneric portions of the unitary support assembly 50 made in accordance with the molding procedure of the present invention.

FIGURE 6 illustrates a further modification of a resilient mounting in accordance with the present invention and involving torsional preloading of first and second elastomeric portions relative to each other. FZGURE 6 shows an end view or an inner tubular mounting member 6% having a laterally extending portion 60L and concentrically spaced in a predetermined location relative to an outer mounting member or tube 6th having peened over ends forming a groove or channel 60g visible in FIGURES 6a and 61) such that an eyelet or ring end of a suspension arm can be mounted and resiliently supported by first and second elastomeric portions relative to the central mounting member or sleeve 60s that can be suitably carried or keyed relative to a shaft. The suspension arm and shaft can be resiliently shackled as is commonly done in suspension systems of motor vehicles. The view of FIGURE 6a illustrates a first elastomeric portion torsionally distorted during molding of a second elasto-meric portion molded simultaneously relative thereto while maintaining the first elastomeric portion in fully distorted condition. FIGURE 6a illustrates a bushing support assembly generally indicated by numeral 60 and including the first elastorneric portion 60s and a second elastorneric portion 60x in equilibrium condition relative to each other. In the event the first and second elastomeric portions are bonded and secured to each other along an interface F there is an additional preloading force in shear between these first and second portions relative to each other once the stressing condition is released relative to the first elastomeric portions while simultaneously molding the second ela storneric portion in situ relative to the inner and outer support members oils and 60t respectively.

A further modification in the bushing assembly is shown in FIGURE 61') wherein there is a unitary support assembly generally indicated by numeral 60A including individual sections 603 of the first el astomeric portions stressed in torsion by turning of the outer support member 60t relative to inner support member 60s and then maintaining the first elastomeric portion in distorted condition while simultaneously molding and bonding a second elastorneric portion 60X relative thereto. The illustration of FIGURE 61) represents the equilibrium condition of the first and second annular elastorneric portions relative to each other as made in a molding procedure in accordance with the present invention.

The laterally extending portion 60L of the inner mounting member 60s is optional and it is also apparent that both the inner and outer members can be cylindrical members concentrically spaced relative to each other and resiliently joined by dual prestressed portions in accordance with the present invention. It is also possible that the inner and outer mounting members can be rectangular or square in cross section rather than cylindrical. In any event, molding apparatus and a method of molding elastomeric matenial relative to such concentric members can be accomplished in accordance with a disclosure of Patent 2,845,657, Beare, issued August 5, 1958, and belonging to the a'ssignee of the present invention. The structures of FIGURES 6a and 6b are suitable for shackle mountings involving resilient bushings to attain predetermined preloading and prestressing in opposite directions. It is also to be understood that first and second elastomeric portions in any of the embodiments can be made of similar or dissimilar resilient materials having difiering characteristics such as relatively greater resilience and softness and the like. Well known resilient or plastic materials such-as natural rubber, butadiene-s-tyrene copolymers, butadieneacrylonitrile copolymers, reclaimed rubber, or compatible mixtures thereof and the like can be used for molding materials adapted to be cured in a suitable manner.

While the embodiments of the present invention as herein disclosed constitute preferred forms, it is to be understood that other forms might be adopted.

What is claimed is as follows:

1. A unitary support assembly comprising, a pair of mounting members, a first resilient means of elastomeric material bonded relative to at least one of said mounting members under a stress that results from movement of the members relative to each other under force such as tension, compression, shear as well as torsion, and a second resilient means also of elastomeric material bonded to each of said'mounting members under an opposing stress complementary to establish an equilibrium condition of preloading in opposite directions, said first and second resilient means each of elastomeric material having direct engagement with each other laterally at least in part at all times.

2. A unitary support assembly comprising, a pair of cylindrical support members concentrically spaced in predetermined positions relative to each other, a first annular elastorneric portion bonded between said pair of members and urged into a torsion ally distorted position, and a second annular elastomeric portion also bonded between said pair of members and contiguous relative to said first portion such that an equilibrium condition is attained in which both said portions are torsionally prestressed in opposite directions.

3. A um'tary support assembly comprising, a pair of plate like-mounting members spaced a predetermined distance from each other, and additional plate-like means -prouided in a position located intermediate said members and adapted to be moved relative to one of said members, a releasable force applicator carried by said additional plate-like means and connected to said one member for use in moving said plate-like means toward said one member, a first resilient portion of elastomeric material bonded both to one said member and said additional plate like means, said force applicator distorting said first :portion in one direction, and a second resilient means of elastomeric material and bonded to each of said mounting members under an opposing stress complementary to establish an equilibrium condition of preloading, said first and second resilient portions each of elastomeric material having direct engagement with each other while at least one of said portions of elastomeric material partially is always between one of said members and said additional plate-like means.

References Cited in the file of this patent UNITED STATES PATENTS 1,486,295 Mullen Mar. 11, 1924 2,017,604 Mountford et al. Oct. 15, 1935 2,044,649 Swennes et al -1 June 16, 1936 2,249,510 Welker July 15, 1941 2,382,372 Wallerstein Aug. 14, 1945 2,650,819 Marlow Sept. 1, 1953 2,911,207 Coble et :al. Nov. 3, 1959 2,917,302 Mattern et al Dec. 15, 1959 FOREIGN PATENTS 691,064 Germany May 15, 1940 

